Alloy foil for liquid-phase diffusion bonding bondable in oxidizing atmosphere

ABSTRACT

The present invention provides liquid phase diffusion bonding alloy foils capable of bonding in an oxidizing atmosphere, which can ensure joints with a homogeneous structure and adequate tensile strength in air in a short period of time using various alloys or Fe-based materials as materials to be bonded; specifically, they are Ni-based liquid phase diffusion bonding alloy foils with compositions comprising as essential components in terms of atomic percent, the diffusion elements B or P at 1.0-20.0% or B and P each at 1.0-20.0%, and Si at 0.5 to ≦15% or 0.5 to &lt;10% and V at 0.1-20.0%, with the remainder substantially Ni and unavoidable impurities, and having a thickness of 3-100 μm. If necessary, one or more types of Cr, Mn or Mo, Co, and/or one or more types of W, Nb and Ti may be selectively included as appropriate. Compositions with a substantially amorphous crystal structure are most effective.

TECHNICAL FIELD

The present invention relates to a Ni-based liquid phase diffusion bonding alloy foil for bonding Fe-based materials such as steel plates, steel pipes and bar steel (including steel wires and reinforcing steel), which allows liquid phase diffusion bonding in an oxidizing atmosphere and can give bonds with excellent bonding strength in a short time.

BACKGROUND ART

Liquid phase diffusion bonding is a bonding method whereby an alloy in the form of a foil, powder plating and having a eutectic composition with a lower melting point than the materials to be bonded is situated and compressed between the materials to be bonded, and the joint is heated to a temperature just above the liquidus of the insert alloy (hereunder referred to as “insert metal”) for melting followed by isothermal solidification, and it is considered to be one type of the solid phase bonding methods. Because liquid phase diffusion bonding allows bonding to be accomplished with relatively low pressure application, it has been conventionally used for bonding which requires absolutely minimal residual stress and deformation by bonding and has mainly been applied for high-alloy steel and heat-resistant steel for which simultaneous welding is difficult, and for bonding between these and carbon steel.

Liquid phase diffusion bonding is most commonly employed for bonding of materials containing at least 0.50% Cr as the alloy composition. Cr-containing materials are characterized by forming dense Cr oxide (usually Cr₂O₃) films on their surfaces, and thus exhibiting excellent oxidation resistance and corrosion resistance. Consequently, the bonding heat also naturally causes formation of oxide films on the bonding surface, and this inhibits wetting of the molten insert metal and considerably interferes with diffusion of atoms which is essential for bonding, so that it has been difficult to obtain satisfactory joints.

For this reasons all such conventional attempts, such as seen in Japanese Unexamined Patent Publications No. 53-81458, No. 62-34685 and No. 62-227595, have tended to entail notable increases in bonding costs, since the vacuum, inertness and reducing property of the bonding atmosphere must be maintained for the liquid phase diffusion bonding.

The present inventors have conducted much research aimed at providing liquid phase diffusion bonding to be employed as a means of bonding stainless steel, high nickel-based alloys, heat resistant alloy steels and other related alloy steels, whereby the liquid phase diffusion bonding can be achieved even when an oxide film is produced on the bonded material surface in air, to give a satisfactory joint in a short time and at a reduced bonding cost, and as a result we have found that such liquid phase diffusion bonding is possible even in an oxidizing atmosphere such as air by using an insert metal containing P or B, or P and B, as the diffusing elements, containing V at 0.1-20.0 atomic percent and having an increased amount of Si.

In other words, it had already been found that while V is the element which increases the melting point of the insert metal, an insert metal with very excellent bonding properties can be obtained by appropriately adjusting the other elements (entirely Si according to the invention), and this is employed for liquid diffusion bonding of primarily stainless steel, high nickel-based alloys, heat resistant alloy steels and these alloy steels with carbon steel, such as already disclosed in Japanese Unexamined Patent Publications No. 2-151377, No. 2-151378, No. 2-185940, No. 7-268521, No. 7-276066, etc. Liquid phase diffusion bonding alloy foil has been proposed which allows bonding of a Ni base containing P or B, or P and B, as the diffusing elements and containing V and Si, in an oxidizing atmosphere.

However, although the aforementioned inventions are all foils with high bonding properties containing large amounts of Si for the purpose of lowering the melting point of the insert metal, they are often unsuitable as bonding alloy foils in cases which demand casting properties for the foils and relatively high toughness for the bonded materials.

Specifically, it often occurs that the elasticity of the foil is reduced rendering it very brittle, or that the Si diffuses into the matrix after liquid phase diffusion bonding, resulting in an unwanted hardness increase and a considerably lower toughness in the so-called weld heat-affected zone.

DISCLOSURE OF THE INVENTION

The present invention provides a Ni-based liquid phase diffusion bonding alloy foil for bonding even Fe-based materials represented by steel materials such as steel plates, steel pipes and bar steel (including steel wires and reinforcing steel) comprising various alloys and carbon steel, which allows bonding in an oxidizing atmosphere and can ensure junctions of homogeneous composition with sufficient applied stress in short periods of time in an oxidizing atmosphere.

The present invention relates to a Ni-based liquid phase diffusion bonding alloy foil which contains Ni as the base and B, Si and V or P, Si and V or P, B, Si and V as essential components, and which can be bonded in an oxidizing atmosphere.

The first invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

B: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The second invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

B: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mn: 0.1-10.0%,

Co: 0.1-15.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The third invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

B: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The fourth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

B: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mn: 0.1-10.0%,

Co: 0.1-15.0%,

and additionally one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The fifth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The sixth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mo: 0.1-15.0%,

Co: 0.1-15.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The seventh invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The eighth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

Si: 0.5-<15.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mo: 0.1-15.0%,

Co: 0.1-15.0%,

and additionally one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The ninth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

B: 1.0-20.0%,

Si: 0.5-<10.0%,

V: 0.1-20.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The tenth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

B: 1.0-20.0%,

Si: 0.5-<10.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mn: 0.1-10.0%,

Co: 0.1-15.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The eleventh invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

B: 1.0-20.0%

Si: 0.5-<10.0%,

V: 0.1-20.0%,

and one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The twelfth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing

P: 1.0-20.0%,

B: 1.0-20.0%,

Si: 0.5-<10.0%,

V: 0.1-20.0%,

and one or more types of

Cr: 0.1-20.0%,

Mn: 0.1-10.0%,

Co: 0.1-15.0%,

and additionally one or more types of

W: 0.1-10.0%,

Nb: 0.1-10.0%,

Ti: 0.1-10.0%

in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.

The thirteenth invention is a liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, according to any of the first to twelfth inventions, characterized in that the crystal structure of the composition is substantially amorphous.

For the purpose of the invention,

“Fe-based material” means a steel material composed of any type of carbon steel containing at least 50% Fe in terms of atomic percent.

“Substantially amorphous” means that at least 50% of the crystal structure of the composition is amorphous. “Liquid phase diffusion bonding” includes diffusion brazing, and is any bonding method whereby an alloy in the form of a foil, powder or plating and having a eutectic composition with a lower melting point than the materials to be bonded is situated and compressed between the materials to be bonded, and the joint is heated to a temperature just above the liquidus of the insert alloy (hereunder referred to as “insert metal”) for melting followed by isothermal solidification; here, melting includes not only a total molten state but also a 50% or greater molten state.

“Oxidizing atmosphere” means an atmosphere which contains at least 0.1% oxygen gas in terms of volume percent of the bonding atmosphere, and has an oxygen partial pressure of at least 10⁻³ atm, i.e. oxidizing power of at least 0.1% in terms of oxygen concentration even when containing a reducing gas such as H₂, H₂S, water vapor or the like.

Unless otherwise specified, “melting point” means the solidus on the phase diagram in the case of alloys which are divalent or of greater valency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view showing an example of liquid phase diffusion bonding with a liquid phase diffusion bonding alloy foil (insert metal), where the materials to be bonded are round steel bonding specimens.

FIG. 2 is a plan view showing an example of a round steel specimen obtained by liquid phase diffusion bonding, where a tensile test piece is also being sampled.

FIG. 3 is a plan view showing an example of a tensile test piece sampled by a tensile test piece sampling apparatus.

FIG. 4 is a graph showing the relationship between the joint tensile strength and the V content of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 5 is a graph showing the relationship between the joint tensile strength and the Si content of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 6 is a graph showing the relationship between the joint tensile strength and the B content of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 7 is a graph showing the relationship between the joint tensile strength and the thickness of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 8 is a graph showing the relationship between the joint tensile strength and the bonding time of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material, also showing a comparison between different cases using a B-based insert metal and a P-based insert metal.

FIG. 9 is a graph showing the toughness of the matrix heat affected zone at a testing temperature of 0° C. after liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 10 is a graph showing the relationship between the joint tensile strength and the P content of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 11 is a graph showing the toughness of the matrix heat affected zone at a testing temperature of 0° C. after liquid phase diffusion bonding using an Fe-based material as the bonded material, also showing a comparison between different cases using a B-based insert metal and a P-based insert metal.

FIG. 12 is a graph showing the relationship between the joint tensile strength and the bonding time of a Ni-based insert metal for liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 13 is a graph showing the toughness of the matrix heat affected zone at a testing temperature of 0° C. after liquid phase diffusion bonding using an Fe-based material as the bonded material.

FIG. 14 is a graph showing the relationship between the joint tensile strength and the Si content of a Ni-based insert metal containing B and P for liquid phase diffusion bonding using an Fe-based material as the bonded material.

BEST MODE FOR CARRYING OUT THE INVENTION

The present inventors have noted the effect obtained with Ni-based liquid phase diffusion bonding alloy foils containing P, Si and V or B, Si and V or P, B, Si and V, such as already disclosed in Japanese Unexamined Patent Publication No. 2-151377, No. 2-151378, No. 2-185940, No. 7-268521, No. 7-276066, etc., and have carried out much research on liquid phase diffusion bonding alloy foils which are not burdened with problems of non-uniform composition, etc. even when bonding Fe-based materials; the inventors have eventually obtained a tough foil wherein the Si concentration is limited to less than 15% or less than 10% as the necessary amount and the other components, particularly P and B, are appropriately limited, and have thus arrived at the present invention as a novel alloy foil composition which has no effect on the matrix material.

This alloy foil is Ni-based, but since the Si concentration is low it can be applied for bonding of iron-based materials, and can give joints with superior properties in the weld heat-affected zone, even when bonding heterogeneous materials such as ferrite-austenite.

(1) According to the first to fourth inventions and the thirteenth invention of the present invention, the Ni-based liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere contains as essential components B as the diffusion element which contributes to a lower melting point, Si which contributes to a lower melting point and V which alleviates the effect of the oxide film; with these components there are included one or more selected from among Cr, Mn and Co which primarily increase the corrosion resistance of the joint or one or more selected from among W, Nb and Ti which primarily increase the joint strength, or there are simultaneously included one or more selected from among Cr, Mn and Co which primarily increase the corrosion resistance of the joint and one or more selected from among W, Nb and Ti which primarily increase the joint strength.

The aforementioned diffusion elements and selected components are combined and added appropriately depending on the component composition for bonding and the intended characteristics of the joint.

B and P are known as diffusion elements, but here B was chosen as a diffusion element which has a larger diffusion coefficient and drastically shortens the bonding time and increases the bonding strength in comparison to P, despite its high bonding temperature of 1050-1300° C.

Thus, the liquid phase diffusion bonding alloy foil of the invention is used mainly for bonding of materials wherein the toughness of the heat-affected zone does not decrease in this temperature range.

(2) According to the fifth to eighth inventions and the thirteenth invention, the Ni-based liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere contains as essential Components P as the diffusion element which contributes to a lower melting point, Si which contributes to a lower melting point and V which alleviates the effect of the oxide film; with these components there are included one or more selected from among Cr, Mo and Co which primarily increase the corrosion resistance of the joint or one or more selected from among W, Nb and Ti which primarily increase the joint tensile strength, or there are simultaneously included one or more selected from among Cr, Mn and Co which primarily increase the corrosion resistance of the joint and one or more selected from among W, Nb and Ti which primarily increase the joint tensile strength.

The aforementioned diffusion elements and selected components are combined and added appropriately depending on the component composition for bonding and the intended characteristics of the joint.

B and P are known as diffusion atoms, but here P was chosen as a diffusion element which has a smaller diffusion coefficient than B and therefore a longer bonding time, but also has a low bonding temperature of 950-1050° C., allowing the heat source unit to be reduced.

Thus, the liquid phase diffusion bonding alloy foil of the invention is used mainly for bonding, for example, Fe-based materials containing Mo which may tend to produce coarse crystal grains and thus exhibit lower toughness at the heat-affected zone when bonded in a high temperature range of 1050° C. and above.

(3) According to the ninth to twelfth inventions and the thirteenth invention, the Ni-based liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere contains, as essential components, B and P as the diffusion elements which contribute to a lower melting point, Si which contributes to a lower melting point and V which alleviates the effect of the oxide film; with these components there are included one or more selected from among Cr, Mn and Co which primarily increase the corrosion resistance of the joint or one or more selected from among W, Nb and Ti which primarily increase the joint tensile strength, or there are simultaneously included one or more selected from among Cr, Mn and Co which primarily increase the corrosion resistance of the joint and one or more selected from among W, Nb and Ti which primarily increase the joint tensile strength.

The aforementioned diffusion elements and selected components are combined and added appropriately depending on the component composition for bonding and the intended characteristics of the joint.

B and P are known as diffusion elements, and here B is used in combination with P so that the complementary action of P will avoid problems such as coarse crystal grains and lower toughness at the heat-affected zone when bonding in a high temperature range of 1050° C. and above, even when the material to be bonded is an Fe-based material containing Mo, for example, and so that the bonding time can be shorter than with P alone.

Thus, the liquid phase diffusion bonding alloy foil of the invention may be applied to a wider range of objects for bonding.

The components included according to the invention will now be explained in connection with the purpose and amounts of their inclusion.

(1) Ni base (Ni included at 50% or greater in terms of atomic percent).

Ni is resistant to oxidation and has a relatively low melting point, so that it is suitable as a bonding material.

(2) B at 1.0-20.0%

B is an element used as a diffusion element to achieve isothermal solidification necessary for the liquid phase diffusion bonding, and also to give a lower melting point than the material being bonded; for these purposes it must be present at a content of 1.0% or greater, but detailed research by the present inventors has shown that if the content exceeds 20.0% coarse Mo- and Cr-containing borides are produced near the joint in cases where the material to be bonded contains Mo and Cr, thus resulting in a lower joint tensile strength, and therefore the range is determined to be 1.0-20.0%.

(3) P at 1.0-20.0%

P is an element used as a diffusion element to achieve the isothermal solidification necessary for the liquid phase diffusion bonding, and also to give a lower melting point than the material being bonded; for these purposes it must be present at a content of 1.0% or greater, but detailed research by the present inventors has shown that if the content exceeds 20.0% coarse metal compounds of 5 μm and greater are produced among the crystal grains on the bonded material side, thus resulting in a lower joint tensile strength, and therefore the range is determined to be 1.0-20.0%.

(4) Si at 0.5-<15.0%

Si is an element effective for lowering the melting point, and it prevents relatively higher melting points and longer bonding times which result from large addition of V. At less than 0.5% the effect is more moderate. At 15.0% and greater coarse Si-containing oxides are produced in the insert metal during liquid phase diffusion bonding in an oxidizing atmosphere, thus impairing the tensile strength and toughness.

However, when B and P are added in combination in the range defined above, the upper limit is preferably less than 10%. When the Si content is 10% or greater accelerated vitrification results in poorer founding properties, a non-uniform thickness and lower tensile strength of the joint.

(5) V at 0.1-20.0%

V is an element which converts the oxide film on the surface of the material being bonded, for example Fe₂O₃ in the case of bonding an Fe-based material, into the low melting point compound oxide V₂O₅—Fe₂O₃ (melting point approximately 800° C.).

Thus, by melting at the bonding temperature (900-1200° C.) and because of spheroidization due to the difference in surface tension in the liquid phase, better wetting of the material being bonded and the insert metal is achieved.

The diffusion elements B and P are very important elements which, being virtually unaffected by the surface oxide film, freely diffuse between the spheroidized oxides to accomplish liquid phase diffusion bonding in an oxidizing atmosphere.

At less than 0.1% the melting of the oxide film is insufficient and fails to give an effect, while at greater than 20.0% the melting point of the insert metal is over 1300° C. making it substantially impossible to achieve liquid phase diffusion bonding.

(6) Cr at 0.1-20.0%

Cr serves primarily to increase the corrosion resistance and oxidation resistance. At less than 0.1% the effect is insufficient, and at greater than 20.0% the melting point of the alloy foil increases dramatically, resulting in poorer productivity and an increase to very high temperatures (1300° C. or higher) which are substantially outside of the range for the liquid phase diffusion bonding temperature.

(7) Mn at 0.1-10.0%

Mn has the effect of increasing the strength by solid dissolution of Ni. At less than 0.1% the effect is insufficient, and at greater than 10.0% it can become a cause of lower joint tensile strength due to poor toughness. The Mn is effective primarily in cases where B is used as the diffusion element.

(8) Mo at 0.1-15.0%

Mo is indispensable for improving the corrosion resistance as is Cr, and especially has an effect of improving the stress corrosion cracking resistance and improving the creep strength at the joint through solid solution reinforcement at high temperatures. At less than 0.1% the effect is insufficient, and at greater than 15.0% coarse metal compounds are produced which cause poor toughness and lower joint tensile strength.

When B is used as the diffusion element, Mo causes deposition of high-melting-point borides at the grain boundaries which impair the toughness and lower the joint tensile strength, and so it is preferably not used when the diffusion element is B.

(9) Co at 0.1-15.0%

Co is added primarily to increase the corrosion and oxidation resistance, and to confer additional strength. At less than 0.1% the effect is insufficient, and at greater than 15.0% coarse intermetallic compounds are produced in the insert metal thus inhibiting toughness of the joint.

(10) W, Nb and Ti at 0.1-10.0% each

W serves to increase the tensile strength of the joint. At less than 0.10% there is no effect, and at greater than 10.0% the high temperature strength is instead lowered due to coarse Laves phase deposition caused by dendritic crystal segregation.

Nb has the effect of enhancing the toughness when diffused in the base material as carbides, nitrides or carbonitrides. At less than 0.1% the effect is insufficient, and at greater than 10.0% coarse intermetallic compounds are often produced which notably impair the toughness of the joint.

Ti serves to increase the tensile strength of the joint, and it also increases the toughness when uniformly dispersed as carbides and nitrides. At less than 0.1% the effect is insufficient, and at greater than 10.0% coarse intermetallic compounds are produced which notably impair the toughness of the joint.

The liquid phase diffusion bonding alloy foil of the invention which has the component composition described above requires uniform melting during the liquid phase diffusion bonding in order to give a satisfactory joint.

With a non-uniform composition, segregation of the alloy components will create a situation in which the melting point of the insert metal will differ depending on the location of the joint, so that the bonding interface will not be homogeneous and a satisfactory joint cannot be obtained.

In fact, in order to avoid a non-uniform composition and segregation of the alloy components, the crystal structure is preferred to be amorphous.

In cases where a uniform composition can be obtained even with a crystalline structure, it is not essential for the crystal structure to be amorphous.

The liquid phase diffusion bonding alloy foil of the invention can be provided as insert metals in various forms.

Alloys with any of the components according to the first to twelfth inventions can be easily produced as amorphous alloy foils by, for example, liquid quenching.

The basic production process employed in this case is a liquid quenching process whereby the molten alloy is blown out through a nozzle onto a cooled substrate and cooled to hardness by thermal contact, and particularly a simple single-roll quenching process may be applied whereby a single cold roll is used as the cooled substrate.

Alternative processes include centrifugal quenching processes using the inner walls of drums and processes using endless-type belts, as well as improvements on these processes involving supplementary rolls or roll surface temperature control devices, and casting under reduced pressure and in a vacuum or inert gas atmosphere is also included. Twin-roll processes whereby the melt is poured between a pair of rolls for quenching solidification may also be applied.

In addition, the alloy may be vacuum melted and cast, and the resulting cast strip is rolled and annealed by a common process to provide the alloy foil.

The alloy foil obtained in this manner will be more advantageous for liquid phase diffusion bonding if it has a smaller thickness since that will result in less variation in mechanical properties near the joint and less time required for bonding, but if the thickness is less than 3 μm the absolute V content in the alloy foil will be insufficient to counter the oxide film on the surface of the material being bonded, while if it is over 100 μm the time required to complete the liquid phase diffusion bonding will increase to 10 hours or more, which is impractical; therefore, the alloy foil is preferred to have a thickness of 3-100 μm.

Although the present invention relates to alloy foils for liquid phase diffusion bonding, the bonding can also be accomplished in air, and thus it can be usefully applied to diffusion brazing bonding methods as well.

EXAMPLES

Liquid phase diffusion bonding of Fe-based materials (carbon steel) as bonded materials was carried out using liquid phase diffusion bonding alloys according to the invention. The conditions employed and the results obtained will now be described along with comparative examples, with reference to the tables and drawings.

Approximately 100 g each of different alloys with component compositions (in atomic percent) according to one of the first to fourth inventions of the present invention were quenched by the single-roll quenching process (cooling roll: Cu alloy, 300 mm diameter), to form alloy foils of substantially amorphous crystal structure, to sheet widths of 2-215 mm and sheet thicknesses of 3-100 μm.

The circumferential speed of the cooling roll at this time was kept between 5.0-15.0 m/s.

The component compositions (atomic percent) of the alloy foils of the invention for these examples, all of which are Ni-based, were as shown in Table 1, where the differences between the totals of the compositions in Table 1 and 100% indicate the total concentrations of Ni and unavoidable impurities.

The component compositions (atomic percent) of the alloy foils for comparison with the alloy foils of the invention are shown in Table 2. As with the alloy foils of the invention, all are Ni-based and the differences between the totals of the compositions in Table 2 and 100% indicate the total concentrations of Ni and unavoidable impurities. The comparison alloy foils in Table 2 were prepared in exactly the same manner as the alloy foils of the invention in Table 1.

Liquid phase diffusion bonding was carried out using the alloy foils listed in Tables 1, 5 and 7 which conform with the first to twelfth inventions and the thirteenth invention of the present invention (hereunder referred to as “insert metals of the invention”) and the comparison alloy foils listed in Tables 2, 6 and 8 (including conventional-type insert metals, hereunder referred to as “comparison insert metals”).

For these examples, the insert metals of the invention were formed into disks of 3-100 μm thickness and 20 mm diameter, and the comparison insert metals into disks of 7.67-234.10 μm thickness and 20 mm diameter, and were sandwiched between round steel (20 mm diameter) and round steel (20 mm diameter) made of an Fe-based material (SKT400) as the material to be bonded, as shown in FIG. 1.

In FIG. 1, 1 is the material to be bonded (round steel) and 2 is the liquid phase diffusion bonding alloy (insert metal).

The liquid phase diffusion bonding atmosphere was air, the bonding temperature was in the range from just above the melting point of each alloy foil to 50° C. above the melting point, and a large-sized heating furnace was used for liquid phase diffusion bonding with the target temperature set to substantially 950-1300° C.

The material to be bonded 2 and the insert metal 3 were both compressed at a pressure force of 2 megapascals (MPa) to improve the adhesion between them.

The bonding time was 10 minutes for all the foils, and, in order to ensure tensile strength, corrosion resistance and toughness of the bonded materials, the bonding was followed by thermal treatment which comprised annealing, quenching+annealing, annealing+tempering or quenching+annealing+tempering, as appropriate either alone or in different combinations.

Mutual diffusion of the elements in the bonded materials occurred during the thermal treatment, promoting homogenization of the joints, and virtually no production, increase or growth of deposits was cast in the insert metals of the invention.

The soundness of the joints was examined with a #JISA2 subsize round steel tensile testing apparatus, and the non-bonded area ratio was 0% in all of the test pieces with insert metals of the invention.

In addition, a #JISA2 tensile test piece such as shown in FIG. 3 was cut out in the axial direction of the round steel from the region shown in FIG. 2, and a tensile tester was used to examine the relative tensile strength of the joint at normal temperature.

The tensile strength for joints is determined by the quality of the materials bonded, the plate thickness and the conditions of the use environment, and for these examples 400 MPa was provisionally set as the minimum required strength based on practical restrictions, and bonds were judged as adequate if a tensile strength at or above this level was obtained. The results of the experiment are shown in Tables 1 to 8 and FIGS. 4 to 13.

Example 1

Embodiments of diffusion bonding alloy foils according to the first to fourth inventions and the thirteenth invention, in which B was included as the diffusion element and Si and V as essential components, will now be explained based on Tables 1, 2, 3 and 4 and FIGS. 4 to 9.

TABLE 1-1 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 1 5.75 13.40 18.76 98 air 543.79 2 2.21 10.91 14.44 17 air 522.19 3 14.36 8.66 10.98 58 air 504.88 4 7.04 12.94 2.63 19 air 463.14 5 8.45 8.61 1.22 52 air 456.08 6 6.58 14.20 7.26 4 air 486.29 7 16.83 8.21 6.57 37 air 482.85 8 9.10 14.97 3.98 62 air 469.91 9 7.85 5.07 10.94 74 air 504.72 10 7.55 13.88 16.57 100 air 532.83 11 18.55 9.10 17.24 1.72 97 air 536.22 12 19.91 5.28 13.46 11.05 78 air 517.32 13 5.28 2.41 6.41 10.63 90 air 482.07 14 12.63 2.99 2.87 1.56 19 air 464.33 15 11.79 7.78 12.59 5.63 54 air 512.97 16 9.65 3.74 7.29 3.09 64 air 486.43 17 13.74 6.44 2.57 6.08 29 air 462.85 18 8.82 3.49 14.39 5.78 86 air 521.95 19 17.05 14.34 10.67 3.43 70 air 503.33 20 7.50 1.22 16.52 16.10 4.53 54 air 532.61 21 16.52 5.51 6.63 14.91 5.92 77 air 483.14 22 12.43 4.66 7.99 0.98 4.01 48 air 489.97 23 2.78 13.43 2.52 9.46 14.75 39 air 462.61 24 13.52 13.54 14.56 6.24 1.54 79 air 522.81 25 1.48 5.32 16.64 5.00 2.58 15 air 533.19

TABLE 1-2 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 26 9.04 6.87 10.17 5.29 5.31 16 air 500.87 27 13.12 9.17 15.85 0.20 10.03 57 air 529.27 28 8.86 1.64 1.30 6.35 13.56 88 air 456.48 29 5.04 9.77 18.89 17.09 4.50 2.61 34 air 544.44 30 10.50 4.60 7.12 3.02 3.12 4.79 65 air 485.62 31 10.20 2.68 8.61 5.77 7.60 12.63 79 air 493.04 32 2.03 14.80 6.84 5.24 21 air 536.59 33 1.92 6.23 15.91 4.22 69 air 571.79 34 3.50 7.54 3.65 8.30 26 air 551.24 35 5.28 2.72 12.71 6.53 52 air 559.29 36 7.56 7.51 15.86 8.60 77 air 589.53 37 6.86 3.99 13.49 0.35 6 air 519.92 38 10.28 4.07 14.67 6.98 49 air 579.18 39 16.84 2.50 19.70 9.85 68 air 627.29 40 14.58 13.09 10.97 1.04 96 air 513.13 41 1.31 5.88 11.35 8.27 8.07 55 air 645.87 42 11.47 2.66 12.91 0.91 1.10 100 air 531.32 43 19.90 9.28 7.65 5.50 7.23 52 air 593.86 44 15.20 14.92 15.18 2.71 4.22 4 air 578.62 45 3.64 7.66 1.91 6.48 0.41 89 air 508.24 46 1.28 3.40 17.12 7.86 6.54 8 air 642.91 47 12.28 9.17 16.97 0.26 5.79 84 air 583.76 48 9.40 8.20 17.78 7.01 4.85 72 air 647.81 49 9.06 10.65 0.24 8.87 8.47 18 air 607.62 50 8.52 11.01 10.85 2.96 4.87 1.35 87 air 578.79

TABLE 1-3 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 51 19.35 1.78 3.51 2.99 4.14 5.16 98 air 567.68 52 7.89 11.59 4.16 8.30 9.12 3.27 47 air 643.82 53 3.20 5.44 11.82 1.97 4.67 100 air 555.78 54 5.98 6.09 14.61 19.62 4.80 88 air 571.07 55 19.73 1.65 16.04 6.85 2.93 39 air 559.51 56 13.45 7.26 3.77 8.92 1.60 6 air 480.03 57 5.29 13.74 6.90 3.27 6.48 72 air 529.84 58 18.48 5.34 16.97 18.56 5.06 11 air 570.26 59 8.24 3.33 14.44 13.27 7.45 50 air 581.78 60 3.23 3.80 19.13 16.97 1.79 46 air 559.98 61 11.52 8.27 10.82 0.28 4.56 69 air 540.54 62 8.01 12.91 16.88 12.18 5.08 2.87 48 air 605.26 63 2.31 7.31 17.72 6.46 8.25 6.59 18 air 667.29 64 6.95 10.81 10.92 19.49 3.69 2.96 78 air 562.23 65 13.57 10.54 6.70 1.73 9.90 3.15 25 air 577.99 66 3.83 0.74 19.45 13.99 6.92 1.89 22 air 610.79 67 10.49 4.79 11.97 16.98 5.56 4.92 13 air 588.18 68 16.93 8.02 11.85 13.13 6.12 1.15 48 air 579.65 69 19.03 10.30 4.35 18.47 0.69 2.97 88 air 502.40 70 17.90 9.27 9.38 19.50 2.50 1.33 11 air 532.55 71 14.05 10.16 18.09 15.28 8.16 1.26 9.99 60 air 710.75 72 13.37 1.69 11.30 2.05 9.50 5.90 2.52 35 air 662.93 73 1.16 4.86 2.19 7.79 1.40 6.22 5.88 7 air 565.52 74 18.79 1.17 11.26 6.44 7.16 30 air 577.92 75 2.57 5.52 7.38 5.79 0.71 56 air 494.03

TABLE 1-4 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 76 3.00 0.57 12.55 1.38 9.06 25 air 603.39 77 3.25 14.34 0.12 3.47 1.66 95 air 462.22 78 16.73 4.28 5.52 1.36 5.00 56 air 512.57 79 13.46 14.52 9.46 9.33 5.47 80 air 535.56 80 17.45 11.89 6.07 0.56 2.29 52 air 498.63 81 5.36 8.64 7.41 2.01 8.58 72 air 555.74 82 11.37 5.43 16.36 1.86 6.06 14 air 580.32 83 19.94 9.42 19.54 3.98 6.37 6.73 52 air 658.47 84 18.80 6.55 8.51 3.67 1.95 6.47 77 air 557.26 85 10.14 7.87 9.88 2.28 3.76 2.77 99 air 556.36 86 6.31 12.93 15.50 3.26 4.62 6.02 47 air 608.02 87 8.62 14.42 10.12 4.79 1.24 2.31 15 air 527.79 88 9.76 6.77 12.39 8.00 4.87 4.60 43 air 582.84 89 18.92 2.30 9.17 3.31 6.54 3.41 54 air 608.50 90 17.14 13.22 7.58 0.34 9.12 5.20 12 air 620.75 91 12.35 1.78 19.88 6.88 8.44 8.04 78 air 698.08 92 2.01 5.56 5.38 0.53 8.03 3.44 0.79 40 air 587.61 93 8.94 1.37 14.46 0.65 2.70 7.06 5.89 26 air 645.90 94 2.24 14.65 15.20 8.95 5.11 5.32 8.74 62 air 684.26 95 5.24 4.56 8.26 14.66 2.15 38 air 512.81 96 5.24 12.68 9.77 10.71 9.81 68 air 596.96 97 2.56 3.85 12.03 10.03 6.40 37 air 574.13 98 7.28 8.93 16.32 13.93 0.49 58 air 535.04 99 8.59 5.03 2.29 2.12 8.08 80 air 518.03 100 5.28 1.94 19.66 11.08 7.53 51 air 601.04

TABLE 1-5 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 101 5.73 8.12 4.63 14.29 4.49 32 air 509.11 102 13.56 8.51 11.30 4.38 2.27 94 air 524.63 103 9.09 14.39 19.92 3.96 6.99 35 air 605.50 104 12.61 12.39 0.97 7.98 9.43 7.39 31 air 600.86 105 13.68 14.57 9.89 6.08 4.37 0.17 68 air 544.30 106 15.04 6.24 18.97 5.04 6.71 0.63 89 air 616.33 107 10.38 7.72 4.44 6.29 7.94 5.01 41 air 567.87 108 3.90 3.65 11.78 1.62 4.59 5.73 81 air 586.88 109 1.87 9.03 6.16 1.33 6.39 9.62 10 air 602.46 110 18.61 13.71 14.65 4.29 6.96 3.76 62 air 622.93 111 15.03 13.44 17.65 7.13 2.18 2.67 57 air 581.38 112 16.13 6.10 9.94 7.13 3.66 3.60 9 air 565.12 113 8.73 14.99 16.12 10.68 2.62 2.47 4.80 12 air 612.51 114 16.22 9.71 11.56 11.10 7.75 3.93 2.39 54 air 632.00 115 9.41 6.86 8.67 8.48 1.42 1.63 9.49 77 air 594.87 116 15.43 8.32 18.91 12.58 2.43 1.97 54 air 564.28 117 1.84 9.33 18.26 10.46 3.12 1.46 9 air 555.91 118 3.45 12.73 2.92 8.02 0.24 1.92 28 air 483.79 119 19.85 10.66 14.55 8.92 1.32 4.38 41 air 553.37 120 8.73 1.68 19.62 18.59 9.64 6.62 29 air 594.40 121 6.60 4.54 16.00 19.71 6.70 6.98 47 air 578.82 122 14.02 10.00 10.87 5.98 5.24 7.34 39 air 563.12 123 6.89 3.11 15.50 1.53 5.23 4.70 14 air 565.09 124 18.23 4.44 3.37 15.58 1.76 9.26 83 air 540.98 125 19.59 3.51 9.24 16.97 6.92 9.10 3.71 77 air 613.17

TABLE 1-6 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 126 14.68 11.52 17.72 7.50 1.08 9.78 0.74 68 air 641.53 127 3.33 0.55 18.05 13.48 8.07 5.96 1.80 4 air 612.46 128 12.43 9.37 5.95 2.80 3.37 4.79 1.06 13 air 521.72 129 9.43 13.00 18.95 11.57 2.23 3.24 9.99 86 air 647.42 130 18.63 12.32 14.87 16.57 0.96 1.46 1.66 51 air 547.84 131 4.05 14.46 19.85 8.98 8.58 9.88 8.32 63 air 714.63 132 2.76 13.99 18.02 2.08 8.72 1.70 5.61 50 air 601.98 133 8.76 9.47 16.01 10.84 8.78 3.96 6.71 36 air 623.38 134 10.54 0.51 8.91 6.58 8.31 7.92 8.51 6.28 51 air 683.54 135 10.11 4.63 5.47 4.12 0.38 3.05 5.18 0.75 99 air 550.07 136 9.33 11.69 19.08 1.22 2.16 3.34 6.82 6.25 65 air 676.50 137 10.55 9.83 17.65 1.15 0.66 9.47 34 air 632.97 138 17.29 12.46 12.09 7.93 14.21 1.22 7 air 522.64 139 8.41 8.03 13.83 9.13 12.29 8.35 11 air 602.65 140 19.93 13.42 5.28 2.40 1.22 2.74 91 air 495.59 141 19.08 10.75 8.33 1.64 3.49 1.58 61 air 502.73 142 8.96 6.26 8.55 2.08 13.29 7.37 30 air 544.36 143 19.70 8.49 3.78 9.92 11.54 4.82 72 air 507.46 144 19.82 10.00 2.63 2.70 11.54 6.36 66 air 514.04 145 8.65 3.98 17.37 3.50 6.39 6.33 38 air 587.53 146 18.60 11.86 17.30 8.61 13.10 9.39 7.32 53 air 681.59 147 3.47 6.18 7.80 4.83 3.45 8.93 8.06 22 air 634.78 148 4.33 5.61 9.58 9.09 14.30 6.56 6.70 10 air 610.39 149 5.80 1.39 11.48 9.22 14.81 9.85 3.09 74 air 601.03 150 1.77 0.78 13.65 5.35 2.30 4.70 9.95 95 air 630.69

TABLE 1-7 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 151 17.51 3.71 11.88 9.82 2.79 1.19 5.36 54 air 560.55 152 12.41 8.65 15.14 1.12 10.50 2.55 0.79 27 air 557.53 153 9.27 6.25 16.86 6.31 7.01 9.60 2.94 82 air 653.83 154 4.75 8.60 11.68 4.66 2.87 8.47 6.41 14 air 644.39 155 9.07 11.92 14.51 1.13 12.13 1.97 5.00 7.34 94 air 636.00 156 3.27 8.36 7.63 1.26 5.60 6.66 5.07 2.04 61 air 606.61 157 9.39 9.71 14.12 6.95 9.22 6.09 7.71 5.98 73 air 683.33 158 9.39 14.16 13.37 12.77 13.49 1.43 79 air 531.13 159 4.44 4.98 17.05 13.41 9.19 8.81 78 air 623.32 160 7.10 10.08 0.16 9.81 7.26 8.69 32 air 537.64 161 10.57 11.31 5.36 14.15 5.49 3.05 58 air 498.15 162 17.55 13.04 8.64 7.46 13.56 6.05 80 air 535.56 163 3.21 4.06 8.46 9.78 12.66 1.69 87 air 504.14 164 10.41 5.17 15.18 0.72 3.89 8.00 75 air 589.86 165 17.30 1.54 1.19 12.62 9.46 3.46 84 air 483.59 166 2.41 12.31 16.30 17.67 11.17 9.43 19 air 606.95 167 13.38 13.77 7.62 16.93 14.76 6.53 9.45 86 air 619.60 168 3.31 11.90 6.59 2.13 7.51 9.71 6.88 56 air 628.23 169 14.64 10.48 15.01 3.53 4.57 9.60 1.75 85 air 633.33 170 13.97 14.46 3.43 0.96 7.40 7.40 2.71 94 air 540.65 171 9.96 10.51 6.06 9.66 3.88 8.33 3.34 21 air 565.31 172 1.86 4.54 16.63 8.01 6.12 9.40 6.91 75 air 654.25 173 3.75 14.62 12.14 13.68 1.99 9.21 1.73 27 air 616.63 174 12.97 7.16 15.68 1.47 7.32 2.80 1.68 54 air 569.88 175 6.83 9.30 15.61 0.76 9.40 4.10 5.05 55 air 609.48

TABLE 1-8 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 176 7.53 2.03 15.40 1.73 12.96 9.01 9.14 6.98 43 air 736.89 177 6.72 8.44 0.14 5.07 0.59 1.57 9.83 5.34 49 air 577.90 178 18.29 1.26 5.32 4.80 0.61 8.38 4.97 7.07 16 air 651.74 179 4.16 5.23 9.53 17.76 1.43 12.13 1.38 98 air 511.44 180 6.64 9.05 10.98 1.77 3.96 10.50 5.36 53 air 558.51 181 17.37 10.70 10.04 4.43 3.75 8.88 8.87 33 air 588.89 182 1.19 13.62 8.33 12.09 0.95 7.12 7.85 53 air 546.60 183 19.49 10.71 4.59 1.52 9.12 9.10 2.08 22 air 487.53 184 16.82 9.44 15.55 0.80 3.97 9.33 7.93 59 air 583.29 185 15.06 1.05 16.12 17.74 6.70 14.45 3.23 78 air 556.42 186 16.48 6.90 14.71 1.67 5.63 5.03 5.41 54 air 566.85 187 14.73 11.50 18.89 13.96 2.16 8.28 4.31 34 air 578.97 188 1.24 2.39 11.33 8.19 6.57 10.21 5.49 6.11 11 air 604.38 189 13.51 4.80 15.08 6.80 8.94 0.98 9.89 8.86 43 air 686.32 190 18.95 13.87 19.88 1.89 4.41 4.05 4.55 7.21 82 air 645.30 191 15.08 6.37 11.30 0.51 8.74 6.82 9.40 3.43 36 air 599.74 192 9.10 12.72 6.01 5.49 9.34 3.89 3.30 5.76 65 air 549.19 193 13.27 11.23 10.00 7.44 4.97 9.10 2.34 5.94 26 air 563.86 194 7.39 2.37 3.71 18.54 7.69 11.72 0.46 3.94 89 air 504.67 195 16.52 14.85 7.92 19.51 3.55 3.38 3.54 4.25 42 air 559.01 196 8.17 9.03 16.15 5.10 0.48 2.14 6.63 7.36 42 air 656.01 197 8.10 12.58 1.30 15.62 2.65 7.62 4.97 9.62 2.67 5 air 594.83 198 12.18 14.97 10.38 3.83 4.34 3.89 7.19 1.19 3.85 37 air 612.98 199 7.62 12.14 18.66 4.93 9.42 12.48 4.88 2.47 4.76 54 air 647.50

TABLE 2 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 200 0.25 10.87 15.60 47.41 air 0.12 201 25.41 10.90 0.15 30.27 air 253.16 202 15.62 0.06 11.11 64.69 air 0.22 203 12.16 20.11 10.15 72.30 air 328.13 204 3.20 4.04 0.02 52.33 air 0.01 205 11.25 12.59 31.44 59.03 air 323.50 206 5.85 6.05 12.51 25.38 59.38 air 176.66 207 4.54 13.83 17.09 18.16 48.16 air 289.02 208 12.07 14.75 10.27 19.95 7.73 air 302.85 209 17.62 12.50 9.13 13.15 11.48 93.12 air 132.07 210 18.83 7.37 6.83 12.66 63.58 air 145.51 211 6.57 1.04 8.63 3.14 14.37 83.45 air 132.82 212 16.79 2.38 2.78 4.45 150.32 air 198.86

TABLE 3 B P Si V Ni B-based insert metal 8.0 5.0 8.0 Base P-based insert metal 8.0 5.0 8.0 Base

TABLE 3 B P Si V Ni B-based insert metal 8.0 5.0 8.0 Base P-based insert metal 8.0 5.0 8.0 Base

As shown in Table 1, a very satisfactory tensile strength of over the target level of 400 MPa was exhibited by joints No.1 to 199 (invention examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were diffusion bonding alloy foils according to the first to fourth inventions and the thirteenth invention.

In contrast, as shown in Table 2, tensile strength of under the target level of 400 MPa, which was completely unsatisfactory, was exhibited by all of the joints No.200 to 212 (comparative examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were comparison alloy foils with compositions or thicknesses not conforming to the invention.

Specifically, No.200 of the comparative examples was a case where the B content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength, while No.201 was a case where the B content was high and coarse borides were abundantly produced at the alloy side of the bond near the joint, thus reducing the tensile strength of the joint.

No.202 was a case where the Si content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength at the joint, while No.203 was a case where the Si content was in excess and coarse SiO₂-based oxides were produced in the insert metal during bonding, thus reducing the tensile strength of the joint.

No.204 was a case where the V content was insufficient so that the oxide film produced on the bonded material alloy surface was not adequately countered and the tensile strength of the joint was reduced, while No.205 was a case where the V content was in excess and the melting point was extremely high, so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced.

No.206 was a case where the abundant presence of Cr resulted in a considerably high melting point so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced, while No.207 was a case where the Mn content was in excess impairing the toughness and reducing the joint tensile strength.

No.208 was a case where the Co content was in excess and coarse intermetallic compounds were produced, reducing the toughness and lowering the tensile strength at the joint, No.209 was a case where the W content was in excess and coarse intermetallic compounds were produced, reducing the toughness and lowering the tensile strength at the joint, and No.210 was a case where the Nb content was in excess, and grain boundary segregation was produced due to overprecipitation of borides, resulting in fragility and reducing the tensile strength at the joint.

No.211 was a case where the Ti content was in excess, and overprecipitation of coarse intermetallic compounds resulted in lower toughness and reduced tensile strength at the joint, and No.212 was a case where the alloy foil thickness was too large, resulting in reduced tensile strength at the joint.

As shown above, liquid phase diffusion bonding using the comparison insert metals which partially satisfied the conditions of the invention but did not satisfy all of those conditions was not able to provide the target joint tensile strength of 400 MPa.

FIGS. 4 to 8 are graphs showing the effects of the components (atomic percent) and thicknesses determined for diffusion bonding alloy foils according to the first to fourth inventions where B was used as the diffusion element, in terms of the relationship between the bonding time and the joint tensile strength (MPa).

FIG. 4 shows the effect of the V concentration in the insert metal on the joint tensile strength. When the V concentration is less than 0.1% in terms of atomic percent, the oxide film on the surface of the bonded material alloy surface is not sufficiently countered and therefore the joint tensile strength is reduced, but in a range of 0.1-20.0% in terms of atomic percent, the joint tensile strength is equivalent to or exceeds that of the matrix (bonded material), and the V effectively acts to counter the oxide film. However, if the V content is greater than 20.0 atomic percent the melting point of the insert metal increases so that the bonding time is inadequate and the joint tensile strength is thereby reduced.

FIG. 5 shows a similar relationship between Si and the joint tensile strength. The joint tensile strength is low when Si is less than 0.5% or greater than 15.0%, but high joint tensile strength is obtained when it is from 0.5 to 15.0%.

FIG. 6 shows the relationship between the B concentration in the insert metal and the joint tensile strength.

When B is less than 1.0% the melting point of the insert metal is high, and when it is over 20.0% the borides produced near the bonding interface lower the joint tensile strength. A high joint tensile strength is obtained when B is from 1.0 to ≦20.0%.

FIG. 7 shows the relationship between the thickness of the insert metal and the joint tensile strength. The tensile strength is clearly inadequate with foils of thickness exceeding 100 μm.

FIG. 8 shows the relationship between the joint tensile strength (MPa) and the bonding time as determined experimentally using B as the diffusion element, with the results compared to using P as the diffusion element. The conditions for the experiment are shown in Tables 3 and 4.

As shown in FIG. 8, Table 3 and Table 4, a higher bonding temperature was required for the invention in which B was used as the diffusion element as compared to using P as the diffusion element, but it was possible to achieve the target joint tensile strength of 400 (MPa) in a shorter time.

FIG. 9 is a graph showing the toughness of the matrix heat affected zone at a testing temperature of 0° C. after liquid phase diffusion bonding, and although the toughness is slightly lower compared to using P as the diffusion element whereby bonding was possible at a temperature of 950° C., superior results were obtained at above the evaluation reference value (50 Pa) even when bonding at a temperature of 1050° C. or higher.

Example 2

Embodiments of diffusion bonding alloy foils according to the fifth to eighth inventions and the thirteenth invention, in which P was included as the diffusion element and Si and V as essential components, will now be explained based on Tables 5 and 6 and FIGS. 10 and 11.

TABLE 5-1 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 1 19.64 0.52 16.03 72 air 530.17 2 16.03 12.32 8.41 54 air 492.05 3 14.63 7.74 8.64 86 air 493.18 4 13.96 4.80 3.58 87 air 467.90 5 6.82 11.22 16.42 85 air 532.08 6 17.99 12.77 17.20 100 air 536.01 7 15.99 1.25 7.16 48 air 485.78 8 4.76 3.75 7.81 21 air 489.05 9 9.20 4.91 2.78 44 air 463.89 10 11.00 0.59 12.30 16 air 511.48 11 10.96 6.26 13.78 5.18 89 air 518.88 12 8.72 13.54 0.83 6.32 75 air 454.17 13 5.03 3.86 10.53 16.00 100 air 502.63 14 16.31 13.66 8.55 3.06 4 air 492.76 15 9.04 2.89 19.31 6.61 52 air 546.53 16 6.65 14.00 7.08 6.54 70 air 485.38 17 14.02 7.10 9.47 14.29 50 air 497.36 18 15.94 3.59 14.81 9.43 55 air 524.04 19 3.65 11.92 18.30 7.33 43 air 541.51 20 17.58 14.46 1.38 16.26 7.01 3 air 456.91 21 8.52 6.94 4.91 7.64 9.76 72 air 474.56 22 1.19 8.55 15.96 0.88 7.84 84 air 529.81 23 17.01 3.69 13.90 6.98 7.79 60 air 519.50 24 8.80 3.57 16.86 12.56 5.80 73 air 534.28 25 6.96 6.75 10.73 12.57 1.47 96 air 503.66

TABLE 5-2 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 26 18.00 0.96 0.17 11.22 6.30 74 air 450.83 27 18.45 1.07 1.36 6.62 7.39 8 air 456.81 28 10.03 9.47 0.14 8.29 7.45 63 air 450.68 29 19.21 4.79 15.13 17.07 0.46 13.34 61 air 525.64 30 15.34 8.01 16.16 12.24 14.21 2.95 91 air 530.79 31 2.98 1.03 4.00 3.85 3.19 2.34 31 air 469.99 32 6.72 7.33 15.88 5.62 24 air 585.57 33 17.21 10.79 17.57 6.44 24 air 602.28 34 15.22 1.96 18.51 7.97 85 air 622.23 35 13.18 3.09 16.46 2.51 47 air 549.89 36 1.25 10.62 1.72 6.89 28 air 506.85 37 12.59 6.39 18.13 0.40 31 air 543.45 38 11.40 10.95 1.83 5.30 99 air 501.51 39 17.02 6.36 2.30 2.13 51 air 478.51 40 19.13 8.79 15.22 1.53 52 air 538.31 41 12.05 1.10 18.56 1.06 6.34 11 air 597.78 42 6.66 9.32 3.82 5.87 0.15 38 air 528.78 43 9.83 12.20 11.53 8.96 3.43 21 air 621.20 44 10.63 5.81 0.51 6.76 7.41 77 air 559.19 45 17.87 10.62 9.06 1.19 0.60 62 air 508.47 46 19.96 7.85 3.49 3.06 8.19 22 air 554.42 47 6.26 11.96 3.05 1.22 6.02 33 air 525.63 48 13.50 6.78 17.98 4.53 9.23 12 air 659.08 49 15.86 8.75 5.04 3.07 6.02 71 air 554.06 50 8.74 1.47 5.15 5.69 1.45 8.22 27 air 658.51

TABLE 5-3 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 51 2.26 2.03 9.41 9.57 6.30 7.85 20 air 699.63 52 12.42 6.63 19.45 1.08 0.30 2.02 5 air 576.29 53 14.25 12.22 13.64 3.05 4.36 71 air 561.80 54 19.58 12.84 9.29 13.96 9.22 37 air 588.69 55 13.38 2.08 14.34 14.08 8.41 49 air 605.77 56 9.66 11.89 4.98 5.64 0.99 11 air 481.82 57 8.99 4.70 15.29 13.66 4.70 87 air 559.34 58 8.21 1.64 17.14 18.10 6.99 42 air 584.61 59 5.32 7.57 12.82 0.70 3.82 34 air 544.62 60 15.32 7.00 2.63 5.02 3.50 26 air 491.10 61 3.45 6.23 11.50 8.58 0.23 39 air 509.38 62 13.72 3.00 4.80 2.86 4.58 0.39 80 air 522.53 63 4.17 14.11 5.57 13.85 4.25 7.97 77 air 576.12 64 14.16 6.48 8.52 8.01 0.23 6.60 52 air 541.07 65 6.97 7.67 16.21 15.77 0.99 5.38 24 air 581.00 66 8.35 12.07 16.22 9.04 3.09 7.72 89 air 614.51 67 15.43 0.93 17.14 19.37 0.33 8.46 98 air 605.75 68 9.93 7.78 16.93 12.91 7.45 7.52 64 air 669.33 69 10.64 1.01 15.29 0.73 9.10 8.62 40 air 686.44 70 9.11 3.64 2.02 5.53 5.51 6.97 23 air 570.95 71 13.95 11.05 7.02 6.75 5.37 2.16 0.13 65 air 554.98 72 6.28 10.39 7.48 13.70 4.79 1.36 3.02 26 air 568.93 73 5.09 14.75 7.94 18.02 3.59 7.88 0.32 93 air 583.38 74 13.46 8.63 5.32 7.06 8.53 30 air 561.93 75 8.45 12.76 13.73 8.65 2.74 90 air 546.07

TABLE 5-4 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 76 15.05 13.99 6.78 2.15 1.64 48 air 500.34 77 6.29 8.20 7.03 4.16 4.01 34 air 513.17 78 18.53 1.38 15.01 1.01 3.31 57 air 548.21 79 2.78 9.50 16.28 1.69 8.11 86 air 588.13 80 2.32 10.10 17.87 9.12 0.34 41 air 542.09 81 3.48 7.70 4.65 8.70 4.83 8 air 511.87 82 16.75 9.30 10.82 12.59 4.55 92 air 540.44 83 7.52 10.29 9.58 6.11 0.82 3.62 74 air 531.42 84 9.42 6.33 1.78 8.79 7.93 5.75 61 air 578.45 85 9.51 4.77 14.50 6.82 1.18 0.20 43 air 535.71 86 15.76 13.23 7.35 10.55 0.30 7.58 72 air 549.49 87 7.20 13.43 4.00 0.60 3.42 6.79 55 air 548.23 88 4.69 12.63 15.62 10.65 0.65 3.86 44 air 563.62 89 7.91 4.66 16.52 4.56 6.07 0.29 42 air 595.67 90 10.64 5.73 9.70 13.64 0.49 1.44 53 air 514.93 91 11.08 12.67 4.61 6.79 2.30 4.78 79 air 534.35 92 16.19 10.92 6.36 4.71 8.62 0.90 7.22 64 air 632.15 93 19.55 8.64 18.79 1.01 3.50 5.75 4.19 66 air 652.66 94 18.07 9.64 10.67 10.31 7.64 6.97 6.31 53 air 679.03 95 5.80 0.63 17.58 2.97 3.57 76 air 573.57 96 9.06 12.65 15.07 2.55 6.11 98 air 586.46 97 9.21 2.88 6.37 3.45 0.34 22 air 485.29 98 6.28 0.70 6.33 3.11 1.09 28 air 489.31 99 10.08 14.65 1.89 1.57 6.27 21 air 503.32 100 18.13 12.55 12.97 3.51 5.64 26 air 554.35

TABLE 5-5 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 101 12.53 11.38 16.52 1.17 2.50 81 air 552.57 102 18.57 8.99 11.54 7.82 1.06 100 air 516.14 103 6.54 13.88 12.87 7.12 3.54 59 air 542.68 104 1.30 5.59 11.31 7.63 8.96 4.76 91 air 629.46 105 12.77 5.52 12.49 0.92 3.15 4.44 88 air 575.12 106 3.81 4.39 8.88 14.19 2.81 6.66 23 air 569.12 107 6.11 4.49 9.51 4.14 5.37 1.80 50 air 549.55 108 10.83 11.92 8.31 12.37 2.28 2.82 54 air 530.01 109 16.24 4.13 10.64 14.84 2.65 8.12 50 air 586.74 110 3.81 7.82 1.88 6.22 3.47 4.46 73 air 529.79 111 8.27 3.62 17.89 10.91 1.46 8.76 25 air 624.17 112 2.34 10.48 9.56 2.04 9.95 6.60 5 air 650.11 113 2.34 2.69 8.58 8.82 4.63 4.05 0.40 91 air 570.71 114 9.24 0.57 8.93 7.36 3.69 5.69 4.84 36 air 610.05 115 10.05 3.87 11.59 6.84 2.63 6.91 8.44 33 air 650.15 116 19.58 5.57 18.77 1.31 14.87 3.15 33 air 575.30 117 3.76 14.94 3.75 6.17 14.35 8.32 21 air 551.95 118 7.10 13.41 14.66 19.11 12.56 4.12 19 air 564.51 119 15.02 14.55 15.52 18.24 11.97 9.78 8 air 596.03 120 8.78 13.94 17.34 18.89 8.49 9.77 29 air 605.07 121 12.31 9.13 9.77 12.79 5.10 2.59 93 air 516.98 122 13.54 2.53 5.79 12.78 7.95 3.38 74 air 506.00 123 5.57 3.95 16.02 10.18 7.78 2.64 39 air 551.20 124 4.65 2.50 6.99 4.97 5.82 4.70 18 air 522.55 125 17.38 7.90 13.53 0.34 7.40 3.02 8.41 28 air 606.71

TABLE 5-6 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 126 16.76 6.12 17.04 13.75 4.73 9.07 5.40 15 air 663.70 127 1.35 13.59 16.58 16.70 6.36 6.27 7.84 17 air 650.51 128 18.08 14.63 9.32 13.13 9.89 2.22 7.98 28 air 575.96 129 6.44 8.06 15.48 15.36 6.71 0.59 7.51 24 air 591.63 130 13.92 13.81 3.90 0.41 12.59 9.96 1.71 56 air 552.91 131 10.80 7.55 14.05 4.54 10.04 9.46 7.24 14 air 672.76 132 7.20 1.15 0.40 0.59 6.02 4.14 6.55 95 air 545.72 133 16.42 9.90 11.04 12.92 3.65 9.06 1.10 65 air 604.58 134 15.64 3.97 1.01 14.36 2.85 9.82 8.63 4.32 72 air 648.24 135 15.64 2.38 5.60 1.07 0.80 7.48 7.40 9.92 9 air 683.93 136 2.66 4.23 8.81 14.01 4.50 8.91 7.16 2.52 64 air 653.41 137 17.69 11.06 5.49 14.85 9.09 0.37 84 air 481.11 138 14.74 3.67 11.79 12.04 0.41 9.14 38 air 600.34 139 2.68 10.85 5.00 4.98 7.18 0.35 21 air 478.47 140 8.69 13.71 2.60 14.71 2.71 3.28 57 air 485.95 141 14.46 4.62 2.58 2.64 3.19 7.54 77 air 515.68 142 3.09 13.57 8.98 9.07 5.50 0.63 85 air 499.34 143 2.69 8.77 18.85 9.89 14.56 7.70 24 air 605.86 144 3.52 3.90 11.44 13.57 14.63 6.80 59 air 561.62 145 12.92 7.31 8.51 6.91 8.70 2.19 36 air 510.06 146 1.17 1.60 3.27 13.96 1.59 1.79 5.96 36 air 525.94 147 11.18 14.03 15.36 13.61 14.03 1.19 1.71 5 air 550.67 148 12.90 3.02 9.93 3.45 11.02 8.24 4.29 42 air 612.09 149 6.15 2.42 5.97 1.25 13.14 7.33 2.18 31 air 548.61 150 13.51 12.13 10.69 14.29 7.69 7.10 6.48 7 air 604.95

TABLE 5-7 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 151 13.65 1.81 1.19 5.73 0.44 7.09 1.09 40 air 514.30 152 5.35 7.79 14.15 9.30 6.26 2.02 8.62 97 air 609.89 153 19.14 4.41 10.11 1.93 5.08 7.27 6.63 86 air 626.31 154 10.62 13.53 6.14 11.07 1.93 7.99 4.57 16 air 597.23 155 1.28 1.48 19.85 6.36 0.19 4.93 7.55 6.71 11 air 705.06 156 11.06 8.61 10.50 10.74 12.02 9.07 6.99 5.19 60 air 683.61 157 1.87 11.69 19.31 1.87 6.63 6.87 3.58 2.32 48 air 658.83 158 11.37 4.71 16.29 14.72 13.85 7.84 16 air 609.82 159 12.33 10.25 9.71 19.98 2.21 7.35 7 air 572.09 160 5.81 1.65 11.99 0.85 8.20 1.25 7 air 522.43 161 16.99 6.96 16.53 17.22 5.08 8.55 6 air 592.52 162 6.05 2.04 13.20 12.02 10.91 7.27 57 air 566.90 163 17.01 3.52 6.34 15.27 13.03 1.52 43 air 492.29 164 1.48 9.72 4.95 17.50 3.95 3.78 86 air 504.97 165 17.38 4.26 6.38 18.35 3.89 5.07 32 air 522.49 166 19.80 6.23 7.23 4.61 7.07 5.46 42 air 529.82 167 4.73 11.75 5.42 11.54 0.14 5.85 1.98 65 air 549.48 168 7.99 13.13 0.37 8.16 4.82 7.08 9.06 43 air 586.01 169 19.98 11.97 19.43 7.20 3.45 5.97 2.68 66 air 625.66 170 10.59 3.85 14.58 9.23 3.94 7.12 0.54 98 air 577.09 171 14.24 12.73 13.92 12.41 3.12 2.98 7.78 65 air 602.75 172 14.35 2.43 18.93 14.17 10.53 1.31 7.99 26 air 617.78 173 4.74 3.84 15.56 13.60 9.72 9.88 6.57 66 air 679.13 174 9.50 9.38 17.20 8.10 6.59 1.46 5.08 86 air 591.21 175 6.60 1.68 1.49 7.11 6.93 6.15 1.20 4 air 528.60

TABLE 5-8 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 176 9.73 8.53 14.54 9.36 7.64 6.83 9.45 6.98 86 air 712.99 177 12.40 11.26 18.81 5.78 2.42 0.47 5.03 4.69 37 air 621.52 178 19.79 6.47 0.74 2.43 1.28 6.19 7.18 3.66 83 air 595.16 179 6.64 4.79 7.74 14.68 2.16 9.93 3.29 27 air 521.64 180 1.74 13.11 11.42 11.28 7.81 9.79 7.20 34 air 579.11 181 19.47 12.63 13.82 1.14 12.77 5.57 1.36 58 air 532.63 182 9.20 5.38 11.50 16.07 6.90 12.74 9.70 68 air 575.37 183 17.57 5.13 15.86 10.57 8.64 7.63 2.37 79 air 545.86 184 18.89 3.71 3.81 18.93 11.04 0.36 9.04 42 air 532.33 185 2.69 3.07 5.73 4.77 4.48 12.62 1.46 83 air 490.31 186 4.25 14.68 8.70 5.76 5.41 9.50 2.21 49 air 511.14 187 15.77 6.37 5.44 11.24 9.44 4.38 9.27 45 air 551.41 188 4.53 4.79 14.17 0.74 10.60 13.46 9.83 2.84 11 air 639.00 189 7.85 7.52 10.14 18.80 2.71 6.81 1.26 3.20 40 air 535.76 190 3.67 0.93 2.20 11.76 1.49 10.87 4.11 7.19 59 air 552.37 191 19.77 11.97 14.98 4.24 1.08 6.30 8.62 0.13 65 air 586.26 192 8.52 7.15 6.38 12.75 4.14 13.65 2.89 3.79 93 air 532.40 193 2.89 1.81 8.19 7.56 5.78 6.14 7.92 0.44 28 air 549.89 194 14.11 12.77 9.97 10.77 5.22 13.32 8.84 4.05 47 air 620.59 195 15.49 3.20 10.69 9.66 5.73 2.31 3.41 4.90 42 air 576.72 196 3.00 8.22 19.26 1.03 0.73 3.50 1.47 5.11 98 air 601.81 197 13.54 2.11 13.29 11.45 7.66 8.89 6.41 1.44 8.13 76 air 655.67 198 8.50 9.16 19.57 5.90 11.33 1.38 2.96 9.35 1.37 16 air 653.85 199 2.55 9.46 18.98 3.91 7.12 3.24 8.21 9.23 4.31 70 air 726.02

TABLE 6 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. P Si V Cr Mo Co W Nb Ti (μm) atmosphere (MPa) 200 0.31 13.64 10.02 12.33 air 0.05 201 24.97 6.80 14.24 21.30 air 179.06 202 17.42 0.04 17.01 78.35 air 0.31 203 12.53 18.16 4.62 5.16 air 327.19 204 13.09 7.95 0.05 69.57 air 0.02 205 14.09 12.55 22.95 24.15 air 341.91 206 5.78 10.44 10.91 23.15 64.65 air 123.71 207 5.14 6.90 8.07 19.93 40.54 air 117.93 208 9.65 14.36 1.07 18.71 42.86 air 198.49 209 4.86 13.47 19.18 14.52 90.92 air 145.05 210 1.86 14.78 18.05 16.17 11.11 air 180.77 211 2.40 9.99 13.40 11.21 1.57 2.95 14.44 84.27 air 214.24 212 15.51 6.32 13.93 8.15 6.16 133.74 air 258.07

As shown in Table 5, a very satisfactory tensile strength of over the target level of 400 MPa was exhibited by joints No.1 to 199 (invention examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were diffusion bonding alloy foils according to the fifth to eighth inventions and the thirteenth invention.

In contrast, as shown in Table 6, tensile strength of under the target level of 400 MPa, which was completely unsatisfactory, was exhibited by all of the joints No.200 to 212 (comparative examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were comparison alloy foils with compositions or thicknesses not conforming to the invention.

Specifically, No.200 of the comparative examples was a case where the P content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength, while No.201 was a case where the P content was high and coarse borides were abundantly produced at the alloy side of the bond near the joint, thus reducing the tensile strength of the joint.

No.202 was a case where the Si content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength at the joint, while No.203 was a case where the Si content was in excess and coarse SiO₂-based oxides were produced in the insert metal during bonding, thus reducing the tensile strength of the joint.

No.204 was a case where the V content was insufficient so that the oxide film produced on the bonded material alloy surface was not adequately countered and the tensile strength of the joint was reduced, while No.205 was a case where the V content was in excess and the melting point was extremely high, so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced.

No.206 was a case where Cr was abundantly present resulting in a considerably high melting point so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced, while No.207 was a case where the Mo content was in excess impairing the toughness and reducing the joint strength.

No.208 was a case where the Co content was in excess and coarse intermetallic compounds were produced, reducing the toughness and lowering the tensile strength at the joint, No.209 was a case where the W content was in excess and coarse intermetallic compounds were produced, reducing the toughness and lowering the tensile strength at the joint, and No.210 was a case where the Nb content was in excess, and grain boundary segregation was produced due to overproduction of borides, resulting in fragility and reducing the tensile strength at the joint.

No.211 was a case where the Ti content was in excess, and overprecipitation of coarse intermetallic compounds resulted in lower toughness and reduced tensile strength at the joint, and No.212 was a case where the alloy foil thickness was too large, resulting in reduced tensile strength at the joint.

As shown above, liquid phase diffusion bonding using the comparison insert metals which partially satisfied the conditions of the invention but did not satisfy all of those conditions was not able to provide the target joint tensile strength of 400 MPa.

FIG. 10 confirms the relationship between the P concentration in the insert metal as determined for diffusion bonding alloy foils according to the fifth to eighth inventions and the joint tensile strength (MPa), showing that when P is less than 1.0% the melting point of the insert metal is high, and when it is over 20.0% the phosphides produced near the bonding interface lower the joint tensile strength. A high joint tensile strength is obtained when P is from 1.0-20.0%.

FIG. 11 is a graph showing the comparative toughness (J) of the matrix heat affected zone at a testing temperature of 0° C. with present invention insert metals using P as the diffusion element and present invention insert metals using B as the diffusion element; when P was used as the diffusion element bonding was possible at a temperature of 950° C., so that coarse crystal grains were adequately prevented at the matrix heat affected zone and products with high toughness were obtained.

The relationship between the joint tensile strength and the V concentration of the insert metal was substantially no different from FIG. 4, the relationship between Si and the joint tensile strength was substantially no different from FIG. 5, and the relationship between the insert metal thickness and the joint tensile strength was substantially no different from FIG. 7, and these are therefore not shown.

The relationship between the joint tensile strength (MPa) and the bonding time in comparison with the invention insert metals using B as the diffusion element were roughly the same as FIG. 8, Table 3 and Table 4, and these are therefore not shown or listed.

Example 3

Embodiments of diffusion bonding alloy foils according to the ninth to twelfth inventions and the thirteenth invention, in which P and B were included as the diffusion elements and Si and V as essential components, will now be explained based on Tables 7 and 8 and FIGS. 12, 13 and 14.

TABLE 7-1 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 1 16.99 11.99 6.14 10.93 20 air 504.64 2 6.05 2.05 9.00 4.85 67 air 474.24 3 19.78 9.96 4.37 8.25 83 air 491.23 4 2.97 6.82 9.29 14.72 77 air 523.58 5 2.83 7.99 2.71 14.56 88 air 522.82 6 19.04 19.73 9.37 11.67 80 air 508.34 7 17.54 4.69 2.05 14.31 26 air 521.55 8 11.06 19.53 3.33 11.77 25 air 508.84 9 18.18 17.47 7.52 5.94 91 air 479.70 10 6.31 13.65 4.75 13.96 18 air 519.82 11 7.59 17.26 7.66 9.15 6.28 28 air 495.73 12 9.55 10.63 9.45 12.46 17.88 12 air 512.28 13 3.36 8.08 6.81 12.75 17.81 66 air 513.77 14 18.85 14.52 8.41 9.30 7.45 29 air 496.51 15 10.91 11.00 7.70 12.37 3.43 25 air 511.87 16 12.45 6.92 7.97 13.04 0.34 10 air 515.22 17 1.18 6.76 8.55 2.73 3.56 11 air 463.65 18 7.86 7.41 4.11 7.15 7.82 66 air 485.73 19 18.63 6.35 8.46 7.23 5.57 20 air 486.13 20 1.34 2.37 2.27 13.05 6.39 8.57 78 air 515.26 21 11.94 8.89 9.24 7.85 10.25 3.81 80 air 489.26 22 14.56 6.06 9.55 1.72 18.75 5.83 71 air 458.60 23 3.07 18.38 7.23 5.32 3.96 12.05 62 air 476.62 24 7.59 3.52 8.97 5.54 9.28 11.03 100 air 477.69 25 11.25 19.09 8.10 14.13 8.51 6.19 15 air 520.67

TABLE 7-2 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 26 3.18 16.03 2.12 11.90 4.74 6.73 97 air 509.52 27 17.47 7.30 2.04 5.49 6.97 5.94 89 air 477.43 28 2.39 7.43 4.47 15.94 18.84 11.98 67 air 529.71 29 6.60 14.89 5.62 11.97 5.36 0.60 14.56 61 air 509.84 30 17.69 14.51 4.49 3.47 15.65 9.85 5.98 81 air 467.37 31 1.95 9.88 2.55 6.41 9.27 9.94 10.51 36 air 482.05 32 19.16 6.39 8.05 15.81 8.50 30 air 614.02 33 3.52 10.90 5.80 10.30 8.89 24 air 590.42 34 17.89 17.16 3.72 17.99 4.97 21 air 589.63 35 18.34 3.11 9.85 18.46 0.67 37 air 547.03 36 15.28 10.73 4.69 19.66 5.48 17 air 586.65 37 2.51 12.09 3.30 0.75 0.57 17 air 457.76 38 12.88 13.28 2.76 5.08 1.43 76 air 486.79 39 2.61 16.01 5.62 12.44 0.49 45 air 516.12 40 16.89 10.01 8.24 2.53 0.93 94 air 470.10 41 15.05 15.98 7.50 13.67 4.54 0.70 22 air 568.66 42 8.88 15.51 8.74 11.51 0.74 0.55 55 air 518.79 43 15.69 5.69 1.24 4.27 4.22 9.81 86 air 582.19 44 3.38 10.15 9.68 17.49 4.44 4.29 71 air 602.90 45 16.92 14.90 5.75 3.55 8.84 1.67 94 air 542.98 46 12.70 12.52 4.74 3.38 3.49 2.04 3 air 507.61 47 1.23 13.36 5.31 15.46 9.95 2.47 59 air 646.51 48 11.49 7.96 4.34 9.52 2.64 5.41 69 air 567.33 49 19.38 9.91 2.69 15.27 6.42 1.24 54 air 600.46 50 19.96 19.78 4.30 1.39 6.15 9.68 5.02 45 air 626.33

TABLE 7-3 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 51 14.65 17.05 9.99 4.11 9.76 4.17 9.48 99 air 673.16 52 7.51 7.76 3.11 18.35 0.88 9.49 4.92 14 air 656.21 53 2.49 17.24 6.85 16.73 18.88 8.49 31 air 618.55 54 5.22 1.74 6.97 10.55 10.78 0.75 6 air 510.28 55 13.88 17.58 3.92 16.32 17.21 9.09 14 air 622.46 56 13.69 3.62 9.11 2.17 10.02 7.83 41 air 515.66 57 15.30 6.30 4.28 1.05 17.25 5.25 70 air 491.99 58 4.95 13.39 9.24 1.02 4.17 0.52 72 air 458.71 59 9.69 17.31 5.52 3.99 18.32 5.44 20 air 513.52 60 9.41 14.20 0.75 11.20 7.81 8.20 56 air 571.54 61 4.65 13.59 9.47 12.29 15.60 4.68 92 air 548.87 62 9.53 12.50 3.41 14.55 9.45 4.72 6.43 82 air 615.00 63 12.24 14.57 3.39 10.30 17.60 2.97 7.66 67 air 584.83 64 5.89 17.74 4.83 8.67 15.68 8.81 6.08 36 air 624.03 65 7.74 19.39 7.24 1.64 13.28 7.87 8.57 23 air 581.87 66 9.19 15.60 4.20 19.31 13.70 3.62 4.63 47 air 608.96 67 1.95 13.45 1.72 2.89 18.95 4.73 8.22 81 air 563.31 68 3.81 19.87 6.07 14.12 0.23 1.60 3.98 35 air 568.45 69 16.69 15.11 8.95 13.22 4.83 2.57 2.65 69 air 562.99 70 9.14 9.46 7.30 0.85 15.51 6.49 5.93 77 air 566.53 71 17.33 19.90 1.82 0.24 15.28 3.60 9.36 7.63 67 air 613.77 72 18.78 6.24 4.37 10.92 0.92 5.42 5.80 1.23 15 air 609.26 73 16.24 4.07 2.96 9.45 11.62 8.20 0.66 0.16 17 air 585.14 74 18.14 4.08 9.57 2.44 7.44 7.98 18 air 542.04 75 17.36 9.40 5.01 13.40 6.08 3.34 26 air 550.42

TABLE 7-4 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 76 9.20 4.73 7.61 13.78 5.47 1.64 56 air 535.33 77 7.32 17.71 2.24 8.99 1.31 2.17 49 air 510.14 78 18.07 7.23 6.18 0.26 9.46 1.92 67 air 464.76 79 3.43 15.34 7.53 9.70 8.50 8.55 61 air 558.34 80 1.47 19.33 6.67 18.48 8.30 1.72 95 air 556.15 81 3.60 16.83 2.47 5.25 8.12 1.58 24 air 488.85 82 17.94 19.67 1.86 10.36 6.25 1.51 48 air 513.90 83 12.68 15.99 0.60 4.62 5.47 3.58 5.41 44 air 546.79 84 18.37 12.70 3.53 15.91 8.76 4.78 5.19 56 air 613.73 85 12.47 12.90 8.13 11.27 2.09 6.76 7.20 87 air 624.32 86 1.47 19.11 3.44 7.56 6.35 2.62 7.89 30 air 569.24 87 14.28 3.76 1.30 11.96 1.31 4.22 9.65 51 air 616.55 88 11.91 2.74 1.41 0.16 7.74 0.51 5.69 77 air 499.93 89 11.40 2.08 6.50 13.11 1.82 0.87 7.47 33 air 583.97 90 17.92 12.85 0.72 11.13 4.44 3.98 2.69 87 air 566.99 91 9.01 13.58 7.81 13.62 0.13 7.23 8.52 97 air 658.52 92 13.93 14.91 9.77 6.62 2.59 8.36 6.67 1.57 42 air 625.96 93 5.45 1.85 4.42 1.23 6.91 4.96 5.89 2.94 51 air 570.48 94 1.29 16.86 9.24 2.32 2.37 3.82 0.28 0.98 86 air 509.61 95 9.00 13.13 6.12 19.73 10.42 4.02 33 air 588.81 96 6.53 11.68 4.10 2.65 6.36 8.39 49 air 547.12 97 15.09 1.86 2.60 18.12 7.78 4.93 12 air 589.93 98 11.44 16.51 0.84 5.65 1.67 2.54 82 air 496.00 99 3.63 1.00 0.56 0.52 8.57 4.55 70 air 484.47 100 6.52 9.23 6.33 6.60 9.96 0.61 22 air 487.26

TABLE 7-5 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 101 3.57 17.61 1.63 16.35 10.93 1.15 75 air 540.93 102 4.96 15.89 2.87 13.47 8.31 6.49 88 air 569.26 103 5.38 5.49 4.87 16.62 13.95 3.24 59 air 559.02 104 15.03 10.74 6.63 19.62 10.35 9.38 6.66 55 air 688.51 105 13.19 2.93 8.98 8.72 1.58 1.72 3.87 75 air 537.89 106 7.27 17.73 3.84 10.08 12.59 9.10 2.14 49 air 606.34 107 9.52 14.60 3.44 6.98 14.46 3.79 7.46 15 air 570.87 108 2.80 17.79 4.87 18.68 8.95 7.36 3.80 8 air 625.31 109 15.91 15.06 5.32 13.04 9.38 0.64 3.94 29 air 551.21 110 9.82 16.22 8.75 9.66 14.40 4.87 1.65 19 air 560.14 111 14.22 5.12 2.69 14.79 5.44 9.60 3.12 70 air 644.87 112 18.96 16.82 4.17 2.30 10.55 7.54 8.12 38 air 601.89 113 18.34 8.63 7.87 5.27 9.75 3.76 6.45 2.99 55 air 583.00 114 12.19 11.54 3.22 2.33 14.66 8.38 6.17 9.84 70 air 667.30 115 5.58 10.59 3.09 17.36 13.08 9.98 8.95 1.84 15 air 714.03 116 13.81 2.15 1.15 11.00 9.14 6.68 5.80 71 air 562.98 117 2.99 13.31 3.59 3.98 10.94 5.63 7.72 4 air 547.06 118 4.27 12.37 8.72 17.23 1.49 1.66 3.21 34 air 568.22 119 14.44 12.65 6.63 17.94 12.18 0.79 0.23 43 air 541.32 120 3.10 3.60 1.32 6.06 15.19 4.56 5.77 74 air 520.71 121 3.37 5.47 7.89 0.30 9.35 9.30 0.64 44 air 456.01 122 4.69 9.49 4.72 16.59 9.20 4.93 2.49 52 air 552.90 123 16.36 18.10 9.35 5.59 16.25 1.27 6.67 38 air 531.29 124 18.74 19.92 4.79 16.32 13.03 0.40 5.44 54 air 575.11 125 16.62 13.90 4.32 14.18 17.42 5.92 8.53 4.20 88 air 635.66

TABLE 7-6 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 126 16.87 17.65 1.99 2.39 15.12 1.38 6.26 5.03 56 air 559.79 127 1.48 5.76 6.40 2.35 17.55 2.03 7.95 8.14 17 air 598.20 128 18.80 6.94 4.46 3.68 8.12 9.76 6.75 2.14 44 air 532.78 129 1.11 15.81 1.48 12.07 14.30 3.21 2.43 4.32 100 air 561.91 130 11.93 5.23 8.40 3.06 16.12 3.46 2.57 0.79 87 air 489.62 131 19.08 8.16 7.14 18.82 15.27 2.66 8.65 1.00 7 air 638.59 132 17.13 4.60 8.32 17.42 9.04 5.89 3.62 9.39 99 air 648.43 133 10.98 6.39 2.21 13.84 15.74 5.27 1.69 8.84 61 air 606.80 134 16.85 10.46 8.23 14.04 18.44 2.76 6.12 7.85 6.24 86 air 686.32 135 6.77 3.49 0.84 18.31 18.13 9.74 4.42 1.74 8.63 8 air 686.98 136 1.62 13.47 5.73 5.58 5.10 5.15 4.90 8.03 0.99 76 air 591.02 137 14.15 10.48 5.36 8.23 8.67 1.05 6.27 82 air 553.86 138 4.73 16.76 7.15 11.75 3.18 5.63 4.94 11 air 558.13 139 13.72 2.53 5.30 17.24 5.38 12.89 0.59 59 air 542.08 140 13.19 12.57 5.24 13.44 9.16 8.39 8.78 76 air 578.61 141 5.18 9.68 5.66 5.41 4.23 4.94 4.82 8 air 510.79 142 11.74 2.46 9.87 5.85 3.54 1.75 6.99 19 air 528.20 143 18.12 13.53 2.09 14.51 3.89 9.77 8.32 28 air 589.07 144 1.09 13.39 0.70 15.57 1.05 7.82 6.09 92 air 576.56 145 2.52 5.11 3.66 9.83 4.23 11.36 9.76 31 air 577.22 146 5.47 3.37 7.69 10.61 7.55 10.08 8.88 1.40 32 air 601.60 147 2.69 13.31 5.40 6.81 6.19 10.93 7.58 1.92 38 air 573.37 148 3.79 16.08 0.64 6.92 0.96 4.58 2.68 4.69 95 air 544.16 149 1.60 5.41 1.46 11.86 4.25 4.05 7.64 3.82 65 air 593.33 150 7.02 12.69 5.62 14.52 2.70 12.87 3.13 2.87 37 air 567.46

TABLE 7-7 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 151 14.59 5.42 8.52 12.04 7.26 8.06 2.79 2.09 27 air 546.45 152 6.38 16.01 6.98 3.47 0.42 5.13 2.29 5.86 66 air 537.16 153 5.88 19.71 4.17 18.92 9.33 9.33 7.47 2.68 46 air 640.72 154 10.70 7.75 7.59 11.22 6.16 7.21 2.36 4.13 83 air 562.75 155 19.16 6.56 8.33 15.66 5.04 5.70 5.55 2.73 3.58 62 air 631.64 156 17.90 1.07 5.80 19.02 2.34 3.45 9.65 4.12 0.38 21 air 673.42 157 16.68 7.14 3.50 15.98 2.07 0.93 5.17 7.65 9.22 84 air 708.92 158 4.08 7.18 4.32 4.15 14.13 0.75 5.76 77 air 528.40 159 5.65 8.88 7.97 7.94 9.42 8.95 9.86 16 air 588.34 160 13.86 19.11 8.10 7.95 8.40 12.81 4.61 69 air 535.85 161 17.27 9.77 5.10 3.34 10.12 6.84 6.59 40 air 512.80 162 5.91 3.61 8.19 18.64 4.65 0.91 6.08 63 air 585.72 163 7.42 8.23 9.28 2.96 3.37 2.36 9.06 35 air 528.22 164 6.60 17.31 2.40 8.18 17.68 12.14 2.19 15 air 508.41 165 12.99 12.53 2.38 5.78 10.22 1.56 1.32 66 air 489.45 166 5.93 11.69 9.88 9.50 13.28 3.52 0.42 19 air 500.84 167 11.66 16.10 8.11 15.03 1.40 14.73 6.05 8.02 14 air 641.83 168 13.58 19.81 0.64 1.66 9.01 8.38 3.38 8.16 18 air 549.16 169 9.60 8.04 6.25 18.94 9.98 4.25 4.14 5.24 59 air 622.75 170 11.39 2.25 7.48 16.95 5.12 0.17 2.58 7.29 49 air 611.15 171 16.09 9.15 4.98 4.90 9.19 10.85 2.87 8.81 74 air 565.04 172 18.66 10.52 9.42 11.71 11.12 5.51 5.43 1.70 40 air 560.20 173 1.08 11.47 5.59 4.89 18.22 13.04 3.37 3.44 38 air 535.60 174 18.07 16.47 6.66 9.98 17.08 14.49 1.28 8.04 19 air 577.07 175 8.61 7.60 9.14 17.57 10.50 4.62 5.56 1.49 4 air 605.36

TABLE 7-8 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 176 6.98 19.70 2.72 15.25 6.66 14.28 3.43 1.57 3.81 93 air 602.00 177 12.64 12.26 7.55 19.05 6.73 4.06 7.75 5.06 4.50 51 air 694.16 178 1.26 16.23 0.78 7.08 16.40 2.76 4.52 2.79 1.24 23 air 560.00 179 19.15 12.04 1.86 15.83 12.02 4.71 13.50 1.03 74 air 539.46 180 16.66 7.18 8.58 17.79 11.57 9.57 0.73 9.83 9 air 637.23 181 6.11 18.32 4.53 4.88 0.74 3.46 6.69 4.49 93 air 519.34 182 15.40 17.62 5.62 2.92 9.69 8.02 11.09 0.32 80 air 466.79 183 7.16 1.64 4.73 12.54 7.58 3.60 1.73 4.33 44 air 543.03 184 12.46 15.78 1.51 13.72 17.38 6.08 14.62 2.61 24 air 536.86 185 8.68 15.99 2.29 14.84 15.08 8.61 13.25 7.95 54 air 587.83 186 14.55 8.10 1.71 2.56 5.32 0.25 4.15 7.24 99 air 520.71 187 5.64 7.62 3.93 3.85 4.19 9.39 1.63 3.44 54 air 496.81 188 16.13 18.42 6.15 1.69 3.22 6.11 2.94 4.29 9.07 68 air 564.83 189 1.03 13.58 2.70 7.42 0.78 5.08 9.01 4.99 6.16 74 air 580.12 190 1.32 2.89 0.93 1.52 15.41 1.01 1.61 0.32 0.97 76 air 467.57 191 17.77 17.93 5.79 18.85 6.78 1.97 6.11 9.35 2.20 5 air 627.29 192 19.57 15.63 8.21 2.06 3.24 3.37 4.63 1.00 5.01 47 air 507.37 193 4.36 17.77 6.39 14.53 16.72 3.94 13.27 2.54 5.97 94 air 588.23 194 18.55 13.88 8.75 6.60 14.40 9.75 5.94 6.83 7.28 86 air 609.55 195 8.55 4.59 9.96 9.27 7.03 9.23 3.11 1.85 5.36 31 air 557.71 196 10.25 18.42 6.30 7.56 6.72 9.75 7.09 7.75 5.31 79 air 607.76 197 4.02 10.59 5.35 8.07 17.72 6.14 5.25 9.15 4.38 7.57 53 air 673.13 198 7.44 13.07 2.78 0.10 2.91 5.83 8.42 8.83 9.26 0.95 38 air 611.21 199 7.12 13.06 7.99 2.15 15.11 1.27 6.92 2.50 3.12 2.66 13 air 528.79

TABLE 8 Alloy foil Tensile Chemical components in alloy foil (atomic %) thickness Bonding strength No. B P Si V Cr Mn Co W Nb Ti (μm) atmosphere (MPa) 200 0.23 19.13 3.66 19.92 35 air 0.12 201 24.10 7.48 4.53 19.46 72 air 154.96 202 11.47 0.82 2.33 6.50 36 air 0.21 203 16.21 22.90 9.36 9.74 16 air 189.12 204 6.42 14.89 0.21 16.09 78 air 0.05 205 1.99 2.92 17.92 4.40 21 air 205.31 206 3.53 15.52 4.35 0.06 72 air 0.15 207 10.71 7.43 3.42 28.24 74 air 311.1 208 14.72 10.57 2.16 7.55 23.95 4.12 32 air 156.41 209 10.58 8.91 1.97 15.39 11.51 1.80 11 air 189.12 210 5.25 10.27 4.57 6.84 16.17 87 air 186.44 211 18.76 17.67 8.25 6.95 1.88 151 air 53.22

As shown in Table 7, a very satisfactory tensile strength of over the target level of 400 MPa was exhibited by joints No.1 to 199 (invention examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were diffusion bonding alloy foils according to the ninth to twelfth inventions and the thirteenth invention.

In contrast, as shown in Table 6, a tensile strength of under the target level of 400 MPa, which was completely unsatisfactory, was exhibited by all of the joints No.200 to 212 (comparative examples) which were obtained by liquid phase diffusion bonding wherein the bonding materials were comparison alloy foils not conforming to the invention.

Specifically, No.200 of the comparative examples was a case where the B content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength, while No.201 was a case where the B content was high and coarse borides were abundantly produced at the alloy side of the bond near the joint, thus reducing the tensile strength of the joint.

No.202 was a case where the P content was insufficient and the melting point was therefore over 1300° C., resulting in markedly lower tensile strength, while No.203 was a case where the P content was high and coarse phosphides were abundantly produced at the bonded material side of the bond near the joint, thus reducing the joint tensile strength.

No.204 was a case where the Si content was insufficient and the melting point was over 1300° C., resulting in markedly lower tensile strength, while No.205 was a case where the Si content was in excess and coarse SiO₂-based oxides were produced in the insert metal during bonding, thus reducing the joint tensile strength.

No.206 was a case where the V content was insufficient so that the oxide film produced on the bonded material alloy surface was not adequately countered and the tensile strength of the joint was reduced, while No.207 was a case where the V content was in excess and the melting point was extremely high, so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced.

No.208 was a case where Cr was abundantly present resulting in a considerably high melting point so that liquid phase diffusion bonding could not be adequately accomplished and the tensile strength of the joint was reduced, while No.209 was a case where the Mn content was in excess impairing the toughness and reducing the joint strength.

No.210 was a case where the Nb content was in excess, impairing the toughness and lowering the joint tensile strength.

No.211 was a case where the insert metal thickness was too large, resulting in reduced joint tensile strength.

As shown above, liquid phase diffusion bonding using the comparison insert metals which partially satisfied the conditions of the invention but did not satisfy all of those conditions was not able to provide the target joint tensile strength of 400 MPa.

FIG. 12 shows the relationship between the bonding time and the joint tensile strength (MPa) for diffusion bonding alloy foils according to the ninth to twelfth inventions and the thirteenth invention, indicating that the bonding time is shorter and a high joint tensile strength is obtained.

FIG. 13 is a graph showing the toughness (J) of the matrix heat affected zone at a testing temperature of 0° C.; even when the bonding was at a temperature of 1050° C. or higher, the toughness was shown to be higher than with insert metals where B was used as the diffusion element (see FIG. 9) and about the same as with insert metals where P was used as the diffusion element (see FIG. 11).

The insert metals in which B and P were added in combination had good amorphous formation, but when the Si content is also high, accelerated vitrification results in poorer founding properties and a non-uniform thickness of the foil.

FIG. 14 shows that because of this decrease, the joint tensile strength is lowered when the Si content exceeds 10%.

The relationship between the joint tensile strength and the V concentration in the insert metal was substantially no different from FIG. 4, the relationship between the joint tensile strength and the B concentration in the insert metal was substantially no different from FIG. 6, the relationship between the joint tensile strength and the P concentration in the insert metal was substantially no different from FIG. 10, and the relationship between the insert metal thickness and the joint tensile strength was substantially no different from FIG. 7, and these are therefore not shown.

The relationship between the joint tensile strength (MPa) and the bonding time was confirmed by results which compared favorably with the insert metals using B as the diffusion element.

As explained above, each of the inventions of the present invention allow bonding of Fe-based materials to be accomplished in a relatively short time, and can ensure adequate bonding strength and toughness of matrix heat-affected zones while also stably ensuring sufficient tensile strength of joints.

In the aforementioned examples the liquid phase diffusion bonding alloy foils are used for bonding of carbon steel, but such bonding is not limited to carbon steel, and the liquid phase diffusion bonding alloy foils may be applied as well to bonding of stainless steel, high nickel-based alloys, heat resistant alloy steels and the like.

INDUSTRIAL APPLICABILITY

According to the present invention it is possible to accomplish liquid phase diffusion bonding of high nickel-based alloys, stainless steel, heat resistant alloy steels and other alloys and Fe-based materials (steel plates, steel pipes, reinforcing steel, bar steel, etc.) in an oxidizing atmosphere, while joints with high tensile strength can also be ensured in a short time, to allow drastic reduction in the time required to accomplish bonding. 

What is claimed is:
 1. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 2. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mn: 0.1-10.0%, Co: 0.1-15.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 3. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0%, in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 4. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing B: 1.0-16%, Si: 0.5%-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mn: 0.1-10.0%, Co: 0.1-15.0%, and additionally at least one element selected from the croup consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0%, in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 5. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 6. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mo: 0.1-15.0%, Co: 0.1-15.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 7. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 8. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mo: 0.1-15.0%, Co: 0.1-15.0%, and additionally at least one element selected from the group consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0% in terms of atomic percent and the remainder substantially Ni and avoidable impurities, and by having a thickness of 3-100 μm.
 9. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 10. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mn: 0.1-10.0%, Co: 0.1-15.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 11. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the croup consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 12. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere, characterized by having a composition containing P: 1.0-20.0%, B: 1.0-16%, Si: 0.5-<10.0%, V: 0.1-20.0%, and at least one element selected from the group consisting of Cr: 0.1-20.0%, Mn: 0.1-10.0%, Co: 0.1-15.0%, and additionally at least one element selected from the group consisting of W: 0.1-10.0%, Nb: 0.1-10.0%, Ti: 0.1-10.0% in terms of atomic percent and the remainder substantially Ni and unavoidable impurities, and by having a thickness of 3-100 μm.
 13. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according claim 1, characterized in that the crystal structure of the composition is substantially amorphous.
 14. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 2, characterized in that the crystal structure of the composition is substantially amorphous.
 15. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 3, characterized in that the crystal structure of the composition is substantially amorphous.
 16. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 4, characterized in that the crystal structure of the composition is substantially amorphous.
 17. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 5, characterized in that the crystal structure of the composition is substantially amorphous.
 18. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 6, characterized in that the crystal structure of the composition is substantially amorphous.
 19. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 7, characterized in that the crystal structure of the composition is substantially amorphous.
 20. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 8, characterized in that the crystal structure of the composition is substantially amorphous.
 21. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 9, characterized in that the crystal structure of the composition is substantially amorphous.
 22. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 10, characterized in that the crystal structure of the composition is substantially amorphous.
 23. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 11, characterized in that the crystal structure of the composition is substantially amorphous.
 24. A liquid phase diffusion bonding alloy foil capable of bonding in an oxidizing atmosphere according to claim 12, characterized in that the crystal structure of the composition is substantially amorphous. 